Edible product comprising reconstituted plant material

ABSTRACT

The present invention relates to an edible product, which comprises a fibrous plant product and a plant extract applied thereto. Further, the invention relates to a corresponding method for producing said edible product and its use in at least one of food, food supplement, medicinal, cosmetic, well-being, nutraceutical or phytotherapeutical applications. The plants used may be all plants comprising one or more substances of interest for an edible product.

RELATED APPLICATIONS

The present application is a divisional application of U.S. patentapplication Ser. No. 14/448,560, which claims priority to U.S. PatentApplication Ser. No. 61/861,541 filed on Aug. 2, 2013, which are herebyincorporated by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to an edible product, which comprises afibrous plant product and a plant extract applied thereto. Further, theinvention relates to a corresponding method for producing said edibleproduct and its use in at least one of food, food supplement, medicinal,cosmetic, well-being, nutraceutical or phytotherapeutical applications.The plants used may be all plants comprising one or more substances ofinterest for an edible product.

BACKGROUND OF THE INVENTION

Today, materials originating from a plant are used in many applications.Such materials are consumed, e.g. as food, food supplement, medicine,for cosmetic reasons or simply for pleasure (taste, color, shape).Native or processed plants can be consumed in different forms, e.g.fresh, dehydrated, cooked, fermented or concentrated (extracts). It isknown that food quality has a major impact on health and that plantbased materials provide many essential nutrients. It is, for instance,recommended to eat five fruits and vegetables a day to receive asufficient amount of essential substances such as proteins, sugars,lipids, amino acids, vitamins, polyphenols and aromatic derivates, aswell as soluble and insoluble fibers.

People tend to complement or even substitute direct vegetal productconsumption (vegetals in their original form) by plant-based material inform of pills, capsules, gums, drops, powders or the like to receivesufficient essential substances. Plant-based material is consumed notonly as food supplement but also as nutraceutics, for beauty (e.g.anti-aging), health or traditional medicine/phytotherapy.

Nature is a source of medicinal products for millennia, with many usefuldrugs developed from plant sources. However, the quality andconcentration of substances and functionality, e.g. color, taste orhumidity of plants, varies depending on the origin of species (seeds),the geographic localization, seasonality, the nature of the soil,growing conditions, harvest date, etc. Further, natural plants cancomprise undesired substances or be contaminated, e.g. with bacterialloads, pesticides, heavy metals, mycotoxins and toxic substances. Stillfurther, the desired substances from a natural plant can in many casesnot be easily extracted during digestion, e.g. the lycopene trapped inthe skin of tomatoes.

There is still a need to improve products originating from plantmaterials, e.g., for nutraceutical or phytotherapeutical or foodsupplement use. In particular, it is desirable to control the amount ofsubstances originating from plant materials as well as conditions andtime needed to achieve a desired effect.

SUMMARY OF THE INVENTION

The invention relates to an edible product comprising plant materials asraw materials. In particular, the edible product may comprise a fibrousplant product and a plant extract. The fibrous plant product maycomprise solid parts of a plant and the plant extract may comprisesubstances extracted from a plant. The fibrous plant product may form alayer on which the plant extract is applied to. The plant extract canform a second layer or at least partially enter or penetrate into thefibrous plant product. Alternatively, the fibrous plant product can haveany shape like pieces, sheets or powder and the plant extract can beapplied likewise to the fibrous plant product. According to theinvention it is possible to first separate substances from one or moreplants and combine one or more of the remaining or separated substancessubsequently.

In the easiest case one plant is separated into a plant extract and afibrous plant product. Subsequently the fibrous plant product and theplant extract are combined to obtain a reconstructed or reconstitutedversion of the original plant with improved properties. For example,certain substances of the original plant may be easily water-soluble andothers not. In this way one can accelerate or even control the releaseor extraction rate of substances. Also, there can be higherconcentrations of certain or all substances as compared to the naturalplant.

The fibrous plant product may have at least partially fibrous propertiesand can comprise substances from one or more specific parts of one ormore plants, e.g. a blend of different plants. Also the plant extractcan comprises substances from one or more specific parts of one or moreplants, e.g. a blend of different plants. Certain substances can bepresent only in certain parts of a plant, e.g. in one or more of theroot, stem, trunk, caulis, leaf, lamina, fruit, flower, seed or bark ofa plant. The plant extract may be soluble, e.g. water-soluble, ordispersible.

The plant extract may comprise one or more substances from one or moretypes of plants of the fibrous plant product. In other words, theplant(s) used as raw material(s) for the fibrous plant product and theplant extract may at least partially be the same.

The plant can be selected from one or more of herbs, medicinal plants,tea, vegetables and/or spices. Examples of plants that are useful inaccordance with the present invention are provided in the list shownbelow. The plant can also be selected from one or more plants containinganthocyanins or carotinoids, or flavonoids. Basically every plant havingone or more desired substances for an edible product can be used, e.g.for food, food supplement, medicinal, cosmetic, well-being,nutraceutical or phytotherapeutical applications. Also, any combinationof two or more plants can be used.

The product may comprise a layer of fibrous plant product on which alayer of plant extract is formed. Also, the plant extract can partiallyor entirely penetrate into the fibrous plant product. Also, amulti-layer product with two or more layers of plant extract can beprovided, each layer comprising certain substance(s) to provide acertain effect. Optionally, the layers in the multi-layer product can atleast partially penetrate into each other. The plant extract can beapplied to the fibrous plant product as a fluid or a gel or a slurry ora powder.

The fibrous plant product may comprise at least about 30% or at leastabout 40% or at least about 50% or at least about 60% or at least about70% or at least about 80% or at least about 90% or about 100% by weightof fibrous plant product from one plant. Similarly, the plant extractmay comprises at least about 30% or at least about 40% or at least about50% or at least about 60% or at least about 70% or at least about 80% orat least about 90% or about 100% by weight of plant extract from oneplant.

Depending on the intended use, the edible product can be a sheet, e.g. apaper like sheet, or a powder or a cream or a slurry or a paste or afoam or a liquid or a tablet or a pellet or a granule. The edibleproduct can be substantially dry, but can optionally be rehydrated, e.g.before use. For example, for use in a food application a dry powder maybe rehydrated with water or other liquids or solvents to obtain anedible composition, e.g. a soup. Also, should the edible product bestored or further processed, e.g. finalized or pre-finalized for aspecific application, it can be in form of a powder or a sheet forstorage or transportation to the finalization process.

The edible product can be one or more of a food, food supplement,medicine, cosmetic, nutraceutical or phytotherapeutic. In the context ofthe invention a food supplement may not only comprise minerals,vitamins, etc. but may further comprise products for altering the tasteor mouthfeel of a food, e.g. spices. Also, the edible product can beused in a method for treating a disease or disorder. Further, theinvention also relates to a kit of parts comprising the edible productaccording to the invention.

The edible product can be produced, at least partially, from certainplants with high level of insoluble fibers. Insoluble fiber is found inthe skins of vegetables and fruit and the bran portion of whole grains.Insoluble fiber helps promote regularity and a healthy digestive system.Insoluble fibers are considered gut-healthy fiber because they have alaxative effect and add bulk to the diet, helping prevent constipation.These fibers do not dissolve in water, so they pass through thegastrointestinal tract relatively intact, and speed up the passage offood and waste through your gut. Natural insoluble fibers are mainlyfound in whole grains and vegetables: whole wheat, whole grains, wheatbran, corn bran, seeds, nuts, barley, couscous, brown rice, bulgur,zucchini, celery, broccoli, cabbage, onions, tomatoes, carrots,cucumbers, green beans, dark leafy vegetables, raisins, grapes, fruit,and root vegetable skins.

The edible product according to the invention can be used for one ormore of a food, food supplement, medicinal, cosmetic, well-being,nutraceutical or phytotherapeutical application.

The invention also relates to a method for producing an edible productaccording to the invention. The method may comprise the steps of:

-   -   a) extracting one or more substances of at least one plant to        obtain a plant extract;    -   b) separating the plant extract from the at least partially        fibrous residue;    -   c) optionally refining the residue;    -   d) preparing a sheet like product from at least a part of the        residue;    -   e) optionally concentrating or purifying or aromatizing the        plant extract;    -   f) applying the plant extract of step b) or e) to the sheet of        step d); and    -   g) optionally drying the product of step f)

It is also possible to select one or more substances or parts from theresidue before a product is prepared in step d). Step e) optionally alsocomprises the selection of certain substances and the filtering ofundesired substances. The selection of plants is similar to therespective discussion relating to the product.

In step a) a solvent can be used to extract the one or more substances.A solvent can be any known solvent, such as a polar protic, apolarprotic, polar aprotic, apolar aprotic solvent. Also a combination ofsolvents can be used. The one or more solvents can be determined basedon the plant(s) to be processed and the substance(s) to be extracted.Alternatively or in addition to a solvent, extracting the one or moresubstances can be achieved by mechanical force. To extract substance(s)via mechanical force the plant(s) can be pressed by any known mechanicalpress or by altering the ambient pressure. Depending on the plant(s) andthe substance(s) to be extracted even a simple filtering can be usedalone or in addition to solvent(s) or mechanical force as some plants,e.g. after cutting, liberate substances, e.g. in form of liquids. Otherfiltering means can be used in combination with mechanical vibration,e.g. to separate solid substances such as pollen, from a plant.

The extracting step can be performed using components of a single plantor of a blend of plants. Also, as explained in combination with theproduct, one or more specific parts of plants can be used.

The at least partially fibrous residue can be mixed with an at leastpartially fibrous part of at least one further plant prior to preparingthe sheet. In this way substances from different origin and withdifferent properties, e.g. mechanical or pharmaceutical, can be mixedtogether to obtain desired product properties. Also, the at leastpartially fibrous residue can be mixed with a stabilizer prior topreparing the sheet. For example, the fibrous residue can be mixed withsynthetic and/or natural fibers to obtain certain mechanical properties,wherein the fibers are preferably non soluble and/or are approved byfood laws.

The plant extract of step b) or e) can be mixed with a plant extract ofat least one further plant prior to applying the plant extract to thesheet. Also, the plant extract of step b) or e) can be mixed with atexturing agent prior to applying the plant extract to the sheet.Texturing agents, e.g. emulsifiers or stabilizers or phosphates or doughconditioners, can be used to add or modify the overall texture ormouthfeel of products. Soluble fibers can also be added to the plantextract to modify dietary properties. Soluble fibers attract water andmay form a gel, which slows down digestion. Soluble fiber delays theemptying of stomach and makes feel full, which helps control weight.Slower stomach emptying may also affect blood sugar levels and have abeneficial effect on insulin sensitivity, which may help controldiabetes. Soluble fibers can also help lower LDL (“bad”) bloodcholesterol by interfering with the absorption of dietary cholesterol.Exemplary sources of soluble fibers are: oatmeal, oat cereal, lentils,apples, oranges, pears, oat bran, strawberries, nuts, flaxseeds, beans,dried peas, blueberries, psyllium, cucumbers, celery, and carrots.

The method may further comprise the step of adding ingredients orremoving ingredients, e.g. undesired compounds or impurities, from theplant extract prior to applying the plant extract of step b) or step e)to the sheet of step d). Similarly the method may further comprise thestep of adding or removing ingredients from the at least partiallyfibrous residue prior to applying the plant extract of step b) or stepe) to the sheet of step d).

The composition of step g) can be further processed to obtain regularlyor irregularly shaped forms or a powder or a cream or a slurry or apaste or a foam or a liquid or a pellet or a granule.

In case a product contains a liquid content, e.g. a paste, a certainamount or substantially the entire plant extract may be solved orextracted from the fibrous plant product or respective pieces of fibrousplant product. In other words, further processing the composition ofstep g) by adding a fluid may change the appearance but the advantagesof the reconstituted product according to the invention remain.

The method may further comprise the step of processing the sheet likeproduct to obtain a powder or a paste or a cream or a slurry. Exemplaryprocessing steps may comprise cutting or grinding. The powder may befurther processed, e.g. to obtain a paste or cream or slurry. The latterstep may be accomplished by adding a fluid to the powder. As explained,even if some or substantially all substances are released from thefibrous plant product, the product according to the invention stillprovides all advantages as all substances are still present, e.g. in thepaste.

According to the invention the edible product can be a fiber-webcomprising from about 5% to about 100% (w/w), preferably at least about10%, at least about 20%, at least about 30%, at least about 40%, atleast about 50%, at least about 60%, at least about 70%, at least about80%, at least about 90%, or about 100%, fibers of herbs, medicinalplants, tea, vegetables and/or spices. The fiber-web may furthercomprise (i) fibers of the herbs, medicinal plants, tea, vegetablesand/or spices, and (ii) synthetic and/or natural fibers such ascellulosic fibers in a ratio of for example: 20/80 (w/w), 30/70 (w/w),40/60 (w/w), 50/50 (w/w), 60/40 (w/w), 70/30 (w/w) or 80/20 (w/w). Inanother embodiment of the invention, the fiber-web of the presentinvention is obtainable by the method disclosed herein, namely as anintermediate product in step d) of the said method.

The fiber-web of the invention may further comprise a coating or animpregnation with the plant extract of said herbs, medicinal plants,tea, vegetables and/or spices. The fiber-web of the present inventionmay be obtainable by the method disclosed herein, namely as the endproduct in step g) of said method.

Further, the invention relates to an edible packing material comprisingthe fiber-web referred to herein, which is either impregnated with theplant extract of said herbs, medicinal plants, tea, vegetables and/orspices or which is not impregnated.

The basic idea of the invention is to process one or more plants toobtain an at least partially fibrous residue and a plant extract. Boththe fibrous residue and the plant extract can be processed and finallycombined to obtain a reconstituted plant product, the properties ofwhich can be controlled depending on the amount and type of substancesused. Also other materials not originating from a plant can be added toalter the properties of the resulting product, e.g. to obtain certainmechanical properties or to add a flavor or to improve control of thereleasing rate of all or certain substances.

The edible product can be consumed, e.g. by eating, drinking,swallowing, gargling, sucking or chewing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross sectional view of one exemplary edibleproduct of the invention.

FIG. 2 is a graph showing total extraction time in hot water for animpregnated edible product as compared to a conventional plant in a bag.

FIG. 3 is a graph showing total extraction time in hot water and theimproved properties as regards the rate substances are released from theproduct according to the invention.

FIG. 4 is a graph showing total extraction time in cold water for animpregnated edible product as compared to a conventional plant in a bag.

FIG. 5 is a graph showing extraction performance of a plant bag of theinvention filled with conventional plant as compared to the extractionperformance of a standard cellulosic plant bag filled with conventionalplant.

FIG. 6 is a graph showing extraction performance of a plant bag of theinvention at a basis weight of 120 g/m² as compared to the extractionperformance of a plant bag of the invention at a basis weight of 60g/m².

FIG. 7 shows reconstituted tea in one example without the use of a wetstrength agent after 3 mins of infusion. The photograph shows thatmaterial is degraded.

FIG. 8 shows reconstituted tea in this example with the use of a wetstrength agent after 3 mins of infusion. The photograph shows that thematerial is substantially undegraded.

FIG. 9 shows a reconstituted material produced according to Example 10.Reconstituted tea (D—high soluble content) shows a higher infusion levelof tea solubles than C (standard soluble level).

FIG. 10 shows a reconstituted material produced according to Example 10.Reconstituted tea A with a lower basis weight shows a faster infusionlevel of tea solubles than C.

FIG. 11 shows the sensorial profile of reconstituted green tea andnatural material.

FIG. 12 shows the sensory analysis of reconstituted rooibos and naturalmaterial (rooibos leaves).

FIG. 13 shows the infusion performance of a reconstituted Rooibosmaterial.

FIG. 14 shows the sensory profile of thyme leaves as compared toreconstituted thyme.

FIG. 15 shows the infusion performance of a reconstituted thymematerial.

FIG. 16 shows the sensory analysis of reconstituted thyme & black tea ascompared to the natural blend.

FIG. 17 shows the sensory analysis of reconstituted laurel & thyme vsnatural blend (laurel & thyme leaves).

FIG. 18 shows the sensory analysis of reconstituted mint vs originalmint material (Menthax piperita).

FIG. 19 shows the sensory analysis of reconstituted mint and green teavs original blend.

FIG. 20A-K shows reconstituted material in different physical shapesthat provide for different kinds of applications.

FIG. 21 shows the infusion performance of a reconstituted coffeematerial.

FIG. 22 shows a photograph of a reconstituted sheet of product placed ona meat and rolled.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a schematic cross sectional view of an edible product, e.g.a chew gum, according to the invention. The first layer 1 comprises afibrous plant product and the second layer 2 comprises a plant extract.The first layer may have a thickness of 100 μm to 0.5 cm, preferably 0.2mm to 5 mm. Instead of having two substantially separate layers, theplant extract can partially or entirely enter or penetrate into thefibrous plant product. The first layer 1 can have a porous structure tofacilitate that the plant extract enters into the fibrous plant product.Also, the fibrous plant product can be small pieces of any shape or apaste or a powder and the plant extract can be applied to the plantproduct.

The product according to the invention may comprise two, three, four,five or more layers, e.g. a first layer 1 comprising a fibrous plantproduct, a second layer 2 comprising a plant extract with firstsubstance(s), a third layer comprising a plant extract with secondsubstance(s), etc. Each layer may comprise different substance(s)offering a specific effect. Also, additional layers or respectivesubstances in the existing layers can be provided for controlling thesequence and/or amount and/or speed substances are released from theproduct.

One or both of the plant extract and the fibrous plant product mayfurther comprise a matrix of a texturizing agent, such as a noncrosslinked hydrocolloid polymer of natural or synthetic origin,preferably of natural origin. The texturizing agent can be selected fromat least one of:

-   -   natural agents of plant origin such as carob gum, guar gum,        pectins, alginates, carrageenans, agar-agar, gum arabic and        cellulose;    -   of microbial origin such as xanthan gum natural agents, gellan        gum, hyaluronic acid and dextran;    -   animal origin, such as gelatin, collagen and chitosan natural        agents;    -   the mineral agents, such as clays and silicas and synthetic        polymers such as polyacrylic and polyacrylamide agents.

The invention can be used in many areas such as for food, foodsupplement, medicinal, cosmetic, well-being, nutraceutical orphytotherapeutical applications. The plants mentioned in connection witha specific application may also be utilized in connection with otherapplications.

The reason for the improved properties of the edible product is due tothe processing of the raw material(s). According to the invention acontrolled amount of selected substances can be placed on the edibleproduct, i.e. in the fibrous plant product or the plant extract. Ifdesired, one plant can substantially be reconstituted or reconstructedso that the final product comprises many or substantially all substancesof the raw material. The reconstructed product is advantageous incomparison to the original plant, as the substances from thereconstructed product can be released in a controlled way, e.g. fasterthan from the natural plant. In addition, it may be desired to mix othersubstances from other plants or synthetical substances into the edibleproduct to alter its mechanical or other properties. Likewise it can bedesired to separate certain undesired substances, e.g. pesticides,metals, polyphenols or substances naturally contained in the plant.

The edible product according to the invention can be used as a spice orcondiment or flavor to supplement or alter the ingredients of a food,e.g. to improve one or more of taste, texture or mouthfeel, or to adduseful substances such as minerals or vitamins. The edible product canbe designed to melt or dissolve in part or completely once it comes incontact with a solvent.

For example, the edible product can be a stock cube or a paper likesheet or can be small pieces or a powder. The edible product can beadded into a hot, warm or cold food or a solvent such as water, e.g. toprepare a soup or sauce or dressing. Substances from the edible productare infused or released into the solvent or food and the edible productcan dissolve in part or entirely. In case the edible product dissolvesentirely in the food, like a stock cube, the plant extract as well asthe fibrous plant product remain in the food. On the other hand, theedible product might only release certain substances, e.g. thesubstances contained in the plant extract and/or a part of substances ofthe fibrous plant product. In the latter case the remaining substances,i.e. what is not dissolved in the food, may be in a form to be separatedfrom the food, e.g. in one piece.

The edible product can be for direct consumption, e.g. by eating,drinking, swallowing, gargling, sucking or chewing. The edible productcan be a sweet, a candy, a chew gum or a sheet like paper. Depending onthe purpose of the edible product, certain substances may be releasedonce the product comes into contact with saliva, i.e. in the mouth.Other substances may remain in the product and only be released in otherdigestion steps. In this way it can be controlled where the respectivesubstance(s) shall unfold its effect.

The edible product can comprise substantially all substances needed byan animal or a human being to survive. In this way the edible productcan be used as alternative to normal food in cases where no or notsufficient food is available or potentially contaminated.

The edible product can be a food supplement to ensure a certain dailysupply of substances such as proteins, sugars, lipids, amino acids,vitamins, polyphenols and aromatic derivates, as well as soluble andinsoluble fibers.

The edible product can be used for making a beverage or a soup. Also,the edible product can be used for providing a herbal, vegetable and/orspice composition. The edible product is a plant-based composition orproduct which is also referred to as plant composition or extractionproduct.

Hereinafter, the aforementioned product or composition is often referredto as “composition(s) or product(s) of the invention”, “composition(s)”or “products”. The herbal, vegetable and/or spice composition is alsoreferred to as “mixture of herbs and spices” or “herbal extraction”.These terms are used interchangeably and are not intended to limit theinvention.

As used herein, the term “plant” likewise refers to any organism of thekingdom Plantae and includes plants described as grains, fruits andvegetables as well as plant parts, such as root, stem, trunk, caulis,leaf, lamina, fruit, flower, seed or bark.

In the products of the invention, the plant is for example selected fromthe group consisting of herbs, medicinal plants, tea, vegetables and/orspices, including mixtures thereof, such as mixtures of herbs andvegetables, or herbs and spices.

As used herein, a spice is a (either fresh or dried) seed, fruit, root,bark, or vegetative substance primarily used for flavoring, coloring orpreserving food. As used herein, herbs are any plants used forflavoring, food, medicine, or perfume. Culinary use typicallydistinguishes herbs as referring to the leafy green parts of a plant(either fresh or dried), from a “spice”, a product from another part ofthe plant (usually dried), including seeds, berries, bark, roots andfruits.

Examples of plants that are useful in accordance with the presentinvention are provided in the list shown below.

The edible product can be a herbal and/or vegetable composition, e.g.,for culinary use or for use in cooking, i.e. as a herb and spicemixture.

The invention further relates to a method for producing the edibleproduct. For example, the method comprises the steps of:

-   -   a) extracting one or more substances of at least one plant to        obtain a plant extract;    -   b) separating the plant extract from the at least partially        fibrous residue;    -   c) optionally refining the residue;    -   d) preparing a sheet like product from the residue, optionally a        sheet like product;    -   e) optionally concentrating or purifying or aromatizing the        plant extract;    -   f) applying the plant extract of step b) or e) to the sheet of        step d); and    -   g) optionally drying the product of step f)

In one embodiment of the invention, one or more plant components (plantmaterial or plant funish) such as, for example, stems, scraps, leaves,fines, dust and/or shorts, are initially mixed with a solvent (e.g.,water and/or other compounds) at elevated temperatures. For example,various solvents that are water-miscible, such as alcohols (e.g.,ethanol), can be combined with water to form an aqueous solvent. Thewater content of the aqueous solvent can, in some instances, be greaterthan 50% by weight of the solvent. In one embodiment, the water contentis at least about 70%, or at least about 80%, or at least about 90% orabout 100% by weight of the solvent. Deionized water, distilled water ortap water may be employed. The amount of the solvent in the suspensioncan vary widely, but is generally added in an amount from about 75% toabout 99% by weight of the suspension. However, the amount of solventcan vary with the nature of the solvent, the temperature at which theextraction is to be carried out, and the type of plant components.

After forming the solvent/plant furnish mixture, some or all of asoluble extracts fraction of the furnish mixture may be optionallyseparated (e.g., extracted) from the mixture. If desired, the aqueoussolvent/plant furnish mixture can be agitated during extraction bystirring, shaking or otherwise mixing the mixture in order to increasethe rate of extraction. Typically, extraction is carried out for about0.5 hours to about 6 hours. Moreover, although not required, typicalextraction temperatures range from about 10° C. to about 100° C.

Prior to the extraction step an optional grinding or cutting step can beused, in order to shred the plant or plant part and thus to break theplant's cell walls.

Once separated from the insoluble residue fraction of the plantsolution, the soluble extracts fraction can optionally be concentratedusing any known type of concentrator, such as a vacuum evaporator. Inone embodiment, the soluble component may be highly concentrated.Moreover, the concentrated or unconcentrated soluble extracts fractioncan be utilized in any manner desired. For example, the soluble extractsfraction can be utilized as a flavoring material or a portion can beadded to the insoluble residue fraction.

Once extracted, the insoluble residue fraction can optionally besubjected to one or more mechanical refiners to produce a fibrous pulp.Some examples of suitable refiners can include disc refiners, conicalrefiners, and the like. The insoluble residue fraction can be utilizedin any manner desired. For example, the insoluble residue fraction canbe used as a flavoring material, used to produce a composition of theinvention, which is herein also referred to as reconstituted plantmaterial.

To produce a product of the invention, the insoluble residue fractioncan be transferred to a papermaking station. The papermaking stationincludes a forming apparatus, which may include, for example, a formingwire, gravity drain, suction drain, felt press, Yankee dryer, drumdryers, etc. In general, the insoluble residue fraction may be in theform of a pulp. In the forming apparatus, the pulp is laid onto a wirebelt forming a sheet-like shape. Excess water is removed from the sheetusing gravity drains, suction drains, presses, and dryers. Thereafter,if desired, a portion of the soluble extracts fraction may be reappliedto the insoluble residue fraction. When the insoluble residue fractionis recombined with the soluble extracts fraction, the resulting plantproduct is generally referred to as “reconstituted plant material”.

Reconstituted plant material can generally be formed in a variety ofways. For instance, in one embodiment, band casting can be utilized toform the reconstituted plant material. Band casting typically employs aslurry of finely divided plant parts mixed with a binder such as gumarabic, guar gum, alginate, xanthan, cellulose and cellulose derivatives(such as carboxy methyl cellulose (CMC), hydroxypropyl methyl cellulose(HPMC)), pectines or starch that is coated onto a steel band and thendried. In one embodiment, the method is performed according to a processsimilar to the conventional tobacco reconstitution process, which is forexample described in U.S. Pat. Nos. 3,353,541; 3,420,241; 3,386,449;3,760,815; and 4,674,519; which are incorporated herein in theirentirety by reference thereto. The method for producing the products ofthe invention can also be performed by a papermaking process, in orderto reconstitute any plant components (such as stems, scraps, leaves,fines, dust and/or shorts) into a paper-like product. Some examples ofsuch processes are described in U.S. Pat. Nos. 3,428,053; 3,415,253;3,561,451; 3,467,109; 3,483,874; 3,860,012; 3,847,164; 4,182,349;5,715,844; 5,724,998; and 5,765,570; which are also incorporated hereinin their entirety by reference thereto for all purposes. For example,the formation of the products of the invention using papermakingtechniques can involve the steps of mixing herbs, medicinal plants, tea,vegetables and/or spices with water, extracting the soluble ingredientstherefrom, concentrating the soluble ingredients, refining the herbs,medicinal plants, tea, vegetables and/or spices, forming a web,reapplying the concentrated soluble ingredients, drying, and threshing.

In the method of the invention, more specifically with respect to thenon-soluble portion (solid plant particles) used in providing thenon-impregnated fiber web of the invention, ie. the sheet-like productin step d), the plant is not tobacco, wood pulp, cotton, textiles, juteflax, Indian hemp, hemp, hoopvine, kenaf, nettles, ramie, aback bamboofiber, banana (especially banana bark), bowstring hemp, coir (fiber fromthe coconut shell), esparto, henequen, kapok, milkweed, papaya, phormium(“New Zealand Flax”), sisal, raffia, bagasse, pina, aibika or yucca.However, a mixture of a plant mentioned herein in connection with thepresent invention with any of the aforementioned plants may be utilized.Further to the foregoing listed materials also others materials can beadded to improve product physical characteristics, for example cellulosederivatives such as methylcellulose, carboxymethyl cellulose (CMC),hydroxypropyl methyl cellulose (HPMC), starch and starch derivativessuch as oxidatively degraded starch, polysaccharides (and theirderivatives) such as pectines, gelatins, guar gum, agar, alginates,carrageenans, or synthetic fibers such as the ones made of vinylchloride or vinyl acetate, polyethylene, polypropylene, polyesters.

Once extracted, the insoluble, solids portion can optionally besubjected to one or more mechanical refiners to produce a fibrous pulp.Some examples of suitable refiners can include disc refiners, conicalrefiners, and the like, well known to a skilled person. The pulp fromthe refiner can then be transferred to a papermaking station thatincludes a forming apparatus, which may include, for example, a formingwire, gravity drain, suction drain, felt press, Yankee dryer, drumdryers, etc. In such a forming apparatus, the pulp is laid onto a wirebelt forming a sheet-like shape and excess water is removed by thegravity drain and suction drain and presses. Once separated from theinsoluble portion of the plant solution (plant extract), the solubleportion can optionally be concentrated using any known type ofconcentrator, such as a vacuum evaporator.

In some embodiments of the invention, a wet strength agent may be addedto the fibrous portion in order to reduce potential degradation of thereconstituted material when it is brought into contact with a liquid(e.g. water), such as upon infusion in water. Any suitable wet strengthagent preferably selected for food applications may be used such aspolyamide-epichlorohydrin resins, polyamine-epichlorohydrin resins,poly(aminoamide)-epichlorohydrin resins, urea-formaldehyde resins;melamine-formaldehyde resins; alkyl ketene dimer; alkyl succinicanhydride; polyvinylamines; oxidized polysaccharides (such asoxidatively degraded starch); glyoxalated polyacrylamide resins;polyimines such as polyethyleneimine. Wet strength agents are well knownto the skilled person and described in Ingredients Standards, such asBFR (Bundesinstitut für Risikobewertung) XXXVI and BFR XXXVI/1 or FDA(Food & Drug Administration) 21 CFR 176.170, FDA 21 CFR 176.110, FDA 21CFR 176.120, FDA 21 CFR 176.1180. The wet strength agent is for exampleused in an amount of about 0.1% w/w to about 20% w/w, preferably ofabout 1% w/w to about 10% w/w, more preferably of about 5% w/w. The wetstrength agent is preferably added to the fibrous portion when or beforemaking the sheet-like product (see step d) above).

In one embodiment, the water used for extraction is hot water,preferably of about 30° C. to 100° C., about 40° C. to 90° C., or about50° C. to 80° C., or more preferably of about 70° C.

In one embodiment, the coating ratio of solubles portion onto the fiberweb is about 5% to 80% (w/w), about 10% to 70% (w/w), or more preferablybetween about 20% and 50% (w/w). In some embodiments, the coating ratioor soluble portion that is added back to the base web (fiber web) issimilar to the portion of soluble material contained in and extractedfrom the original plant (so called “standard level”).

In one embodiment, the base weight of the final product is about 20 toabout 200 g/m² (dry basis), more preferably about 90 g/m² to about 120g/m².

The extraction time depends on the herbs, medicinal plants, tea,vegetables and/or spices subjected to the extraction process. In oneembodiment of the invention, the extraction time is about 15 to 60minutes, preferably 45 minutes.

In one embodiment of the method of the invention, the extracting step isperformed using components of a blend of plants, in another embodiment,extracting step is performed using components of a single plant.

Extraction may also be performed by means other than using hot water,namely by extraction with supercritical gases, such as carbon dioxide,or by using, for example, ethanol, hexane, acetone, R134a(1,1,1,2-tetrafluoroethane), carbon dioxide and hydrofluorocarbons. Inone embodiment, the extraction can be carried out by using at least onesolvent at room temperature and under atmospheric pressure. Extractionmay also be performed by using a mixture of different solvents. Inanother embodiment, extraction may be performed using at least onesolvent, such as for example R134a or carbon dioxide, at differenttemperatures and at different pressures and different states (liquid orgaseous). For example, extraction may be performed using solvents in aliquid state (such as solvent that are volatile or non-volatile at roomtemperature), in a subcritical state (such as water at a temperatureabove 100° C. and a pressure above 1 bar), or in a supercritical state(such as carbon dioxide at a temperature above 31° C. and a pressureabove 73 bar).

Certain plants may require specific extraction conditions (time,temperature, solid/liquid ratio) due to the ingredients containedtherein, which may be temperature sensitive or must not be subjected tocertain extraction conditions. For example, extraction of lycopene fromtomatoes must be performed by using specific enzymes to liberate theproduct from tomatoes cells. In connection with the present invention,processing aids may be used to improve extraction, such as pH modifiers(such as, for example, NaOH or organic acids), microwaves, pressure,ultrasound, enzymes such as for example proteases, amylases, cellulose,and/or pectinases. Whenever reference is made herein to “extraction”,the term includes the aforementioned alternative extraction means. Theextraction used in connection with the present invention can beperformed in a continuous or discontinuous matter. The extractionconditions are well known to the skilled artisan and described instandard text books, such as Handbook of Separation Techniques forChemical Engineers, Third Edition (March 1997), Philip A. Schweitzer,McGraw-Hill Inc.

In one embodiment, the extraction and/or pressing may be performed usingat least a portion of the plant material, fresh, frozen or dried,selected from one or more of root, stem, trunk, caulis, leaf, lamina,fruit, flower, seed of bark.

Separation of the soluble portion (plant extract) from the non-solubleportion (solid plant particles) can be performed by separating theliquid phase from the solid phase, such as by filtration, with orwithout pressure, by centrifugation or other methods commonly used inthe laboratory and well-known to the skilled person.

In one embodiment of the method where a mixture or blend of plants isused, the non-soluble portion of the plant is mixed with the non-solubleportion of at least one further plant prior to preparing the sheet.

Certain embodiments of the method of the invention use the solubleportion of step b) or concentrated soluble portion of step e), which ismixed with the soluble portion or concentrated soluble portion of atleast one further plant prior to applying the soluble portion orconcentrated soluble portion to the sheet.

For certain applications it is desirable to adjust the composition byadding or removing ingredients or components to or from the plantextract and/or the non-soluble plant particles prior to producing thefinal product of the invention. Such adjustment may be performed tomodify/improve chemical, physical and/or sensory characteristics of thefinished product. The invention thus encompasses methods, furthercomprising the step of adding or removing ingredients from the solubleportion (plant extract) and/or from the non-soluble portion (solid plantparticles) prior to applying the soluble portion of step b) orconcentrated soluble portion of step e) to the sheet of step d).

In some embodiments, the sheet or sheet-like product which is obtainedin step g) is a web or fiber-web. The sheet-like product or web may beused in different sizes and shapes. In some cases, the composition ofstep g) is further cut or broken into small regularly or irregularlyshaped forms or processed to obtain a powder, e.g. by grinding. Inaddition to cutting or breaking the sheet or fibrous web to a desiredsize and/or shape, it may be dried to the desired final moisturecontent.

Also, product can be supplied to food industries in sheet or bobbinforms which can be later used as an ingredient for food manufacturing.It is indeed a very convenient option to store, manipulate and adjustdosage of herbs or spices.

One possible grinding method is cryogenic grinding. Cryogenic grinding,also known as freezer milling, freezer grinding, or cryomilling, is theact of cooling or chilling a material and then reducing it into a smallparticle size. Heat and oxidation reactions usually occur on thematerial with standard grinding technologies, at room temperature.Thanks to cryogenic grinding, enzymes, vitamins and many other activemolecules are preserved from such reactions. This technology is used toprepare medicinal plant powders.

The product according to the invention may also be pelletized, e.g. toproduce tablets or granule. Pelletizing is the process of compressing ormolding a material into the shape of a pellet. Ingredients are normallyfirst hammered to reduce the particle size of the ingredients.Ingredients are then batched, and then combined and mixed thoroughly bya feed mixer. Once the feed has been prepared to this stage the feed isready to be pelletized. Pelletizing is done in a pellet mill, where feedis normally conditioned and thermally treated in the fitted conditionersof a pellet mill. The feed is then pushed through the holes and a pelletdie and exit the pellet mill as pelleted feed. After pelleting thepellets are cooled with a cooler to bring the temperature of the feeddown. Other post pelleting applications include post-pelletingconditioning, sorting via a screen and maybe coating if required.

In accordance with the present invention the plant is selected from thegroup consisting of herbs, medicinal plants, tea, vegetables and/orspices, including mixtures thereof. The following list of plants (suchas herbs, medicinal plants, tea, vegetables and/or spices) referred toherein provides an overview of exemplary plants that can be used inconnection with the invention. It is noted that the list is notlimiting, as any plant having one or more substances desired for use inan edible product can be utilized. Also, two or more plants may be usedtogether in a product according to the invention. Examples of plantsthat are useful in accordance with the present invention are:

Abelmoschus spp., Abies spp., Abroma augusta, Acacia spp., Acalyphaindica, Acanthus mollis, Acer spp., Achillea spp., Achyranthesbidentata, Acmella oleracea, Acorns calamus, Actaea spp., Actinidiaspp., Adansonia digitata, Adiantum spp., Adoxa moschatellina, Aegopodiumpodagraria, Aesculus spp., Aframomum spp., Agathosma spp., Agave spp.,Agrimonia spp., Ajuga spp., Alaria esculenta, Albizia spp., Alcea rosea,Alchemilla vulgaris, Aletris farinosa, Alisma spp., Alliaria petiolata,Allium spp., Alnus spp., Aloe spp., Aloysia citriodora, Alpinia spp.,Althaea officinalis, Amaranthus spp., Ammi visnaga, Amomum villosum,Amorphophallus konjac, Amyris balsamifera, Anacardium occidentale,Ananas comosus, Andrographis paniculata, Anemarrhena asphodeloides,Angelica spp., Angostura trifoliata, Aniba rosaeodora, Annona spp.,Anogeissus latifolia, Anredera baselloides, Antennaria dioica, Anthemisspp., Anthriscus spp., Anthyllis vulneraria, Antirrhinum majus, Aphanesarvensis, Apium graveolens, Arachis hypogaea, Aralia spp., Arbutusunedo, Arctium spp., Argania spinosa, Armoracia rusticana, Artemisiaspp., Artocarpus altilis, Ascophyllum nodosum, Asimina triloba,Aspalathus linearis, Asparagus spp., Asplenium spp., Astracantha spp.,Astragalus spp., Astrantia major, Athamanta macedonica, Atractylodesspp., Avena spp., Averrhoa carambola, Baccharis genistelloides, Bacopamonnieri, Bactris gasipaes, Balanites aegyptiaca, Ballota spp., Bambusaspp., Barbarea spp., Bellis perennis, Berberis spp., Bergeniacrassifolia, Bertholletia excelsa, Beta vulgaris, Betula spp., Bixaorellana, Blainvillea acmella, Borago officinalis, Boronia megastigma,Boswellia spp., Brassica spp., Bupleurum spp., Bursera tomentosa,Caesalpinia bonduc, Cakile maritima, Calendula spp., Calluna vulgaris,Calophyllum inophyllum, Camelina spp., Canarium acutifolium, Canavaliaensiformis, Cannabis sativa, Capparis spinosa, Capsella bursa-pastoris,Carex arenaria, Carica papaya, Carissa carandas, Carlina spp., Carpinusbetulus, Carthamus spp., Carum carvi, Cassia spp., Castanea sativa,Catalpa bignonioides, Ceanothus americanus, Cecropia peltata, Cedruslibani, Ceiba pentandra, Centaurea spp., Centaurium erythraea, Centellaasiatica, Centranthus ruber, Cerasus spp., Ceratonia siliqua, Cercissiliquastrum, Ceterach officinarum, Cetraria islandica, Chaenomelesspeciosa, Chamaemelum nobile, Chamaecrista nomame, Chelone glabra,Chenopodium spp., Chimaphila umbellata, Chiococca alba, Chionanthusvirginicus, Chlorella vulgaris, Chondrus crispus, Chrysanthellum spp.,Chrysophyllum cainito, Chrysopogon zizanioides, Cichorium spp., Cinchonaspp., Cinnamomum spp., Cistanche salsa, Cistus spp., Citrullus lanatus,Citrus spp., Cladonia rangiferina, Clematis spp., Clinopodium vulgare,Clitoria ternatea, Cnicus benedictus, Cochlearia officinalis, Cocosnucifera, Codonopsis pilosula, Coffea spp., Coix lacryma-jobi, Colaspp., Combretum spp., Commiphora spp., Conyza canadensis, Copaiferalangsdorffii, Coptis spp., Corallina officinalis, Cordia myxa,Coriandrum sativum, Cormus domestica, Cornus spp., Corrigiolatelephiifolia, Corylus avellana, Corymbia citriodora, Cosciniumfenestratum, Cotinus coggygria, Crambe maritima, Crataegus spp.,Crithmum maritimum, Crocus sativus, Crossostephium chinense, Crotonnitens, Cruciata laevipes, Cryptocarya agathophylla, Cucumis spp.,Cucurbita maxima, Cuminum cyminum, Cupressus sempervirens, Curcuma spp.,Cuscuta spp., Cyamopsis tetragonoloba, Cyathula officinalis, Cyclantherapedata, Cydonia oblonga, Cymbopogon spp., Cynara spp., Cyperus rotundus,Cytinus hypocistis, Daemonorops draco, Dahlia pinnata, Daucus carota,Dendranthema grandiflorum, Descurainia sophia, Dianthus caryophyllus,Dimocarpus longan, Dioscorea spp., Diospyros spp., Diplotaxistenuifolia, Dipsacus spp., Dorstenia contrajerva, Dracocephalummoldavica, Drimys winteri, Drosera spp., Dunaliella salina, Duriozibethinus, Durvillea antartica, Dysphania botrys, Echinacea spp.,Echium plantagineum, Elaeis guineensis, Elettaria cardamomum,Eleutherococcus senticosus, Elymus repens, Epilobium spp., Equisetumspp., Erica spp., Eriobotrya japonica, Eriodictyon californicum, Erodiumcicutarium, Eruca vesicaria, Eryngium campestre, Eschscholtzia,Eucalyptus spp., Eucheuma spp., Eucommia ulmoides, Eugenia uniflora,Euphrasia spp., Euterpe oleracea, Evernia prunastri, Exostema caribaeum,Fabiana imbricata, Fagopyrum esculentum, Fagus sylvatica, Fallopia spp.,Ferula assa-foetida, Ficus spp., Filipendula spp., Foeniculum vulgare,Forsythia suspensa, Fragaria spp., Frangula spp., Fraxinus spp., Fucusspp., Fumaria officinalis, Galega officinalis, Galeopsis segetum, Galiumspp., Garcinia spp., Gardenia jasminoides, Gastrodia elata, Gaultheriaprocumbens, Gelidium spp., Gentiana lutea, Geranium spp., Geum spp.,Ginkgo biloba, Glycine max, Glycyrrhiza spp., Gossypium herbaceum,Gracilaria gracilis, Griffonia simplicifolia, Grindelia spp., Guaiacumspp., Guazuma ulmifolia, Gynostemma pentafillum, Gypsophila paniculata,Haematococcus pluvialis, Haematoxylum campechianum, Hamamelisvirginiana, Handroanthus impetiginosus, Haplopappus baylahuen,Harpagophytum spp., Hebanthe eriantha, Hedeoma pulegioides, Hederahelix, Hedychium coronarium, Helianthus spp., Helichrysum spp.,Heracleum sphondylium, Herniaria spp., Hesperis matronalis, Hibiscussabdariffa, Hieracium pilosella, Hierochloe odorata, Himanthaliaelongata, Hippophae rhamnoides, Hizikia fusiformis, Hordeum vulgare,Houttuynia cordata, Humulus lupulus, Hydrangea arborescens, Hygrophilaauriculata, Hymenaea courbaril, Hypericum perforatum, Hyssopusofficinalis, Ilex paraguariensis, Illicium verum, Impatiens balsamina,Indigofera tinctoria, Inula spp., Ipomoea batatas, Isatis tinctoria,Jasminum spp., Jateorhiza palmata, Juglans spp., Jumellea fragrans,Juniperus communis, Justicia spp., Kaempferia galanga, Kavalama urens,Kickxia spuria, Knautia arvensis, Krameria lappacea, Lactuca spp.,Lagerstroemia speciosa, Laminaria spp., Lamium album, Larix spp., Laurusnobilis, Lavandula spp., Lawsonia inermis, Ledum palustre, Lensculinaris Medik, Leonurus cardiaca, Lepidium spp., Leptospermum spp.,Lespedeza capitata, Leucanthemum vulgare, Levisticum officinale, Liliumbrownii, Linaria vulgaris, Lindera aggregata, Linum usitatissimum,Liquidambar styraciflua, Litchi chinensis, Lithothamnion calcareum,Litsea cubeba, Lobaria pulmonaria, Lonicera japonica, Lotus spp., Lumachequen, Lycium spp., Lycopersicon esculentum, Lycopodium clavatum,Lycopus spp., Lysimachia vulgaris, Lythrum salicaria, Macadamiaternifolia, Macrocystis pyrifera, Magnolia spp., Malpighia glabra, Malusspp., Malva sylvestris, Mammea americana, Mangifera indica, Manihotesculenta, Manilkara zapota, Maranta arundinacea, Marchantia polymorpha,Marrubium vulgare, Marsdenia spp., Mastocarpus stellatus, Matricariachamomilla, Medicago sativa, Melaleuca spp., Melilotus spp., Melissaofficinalis, Melittis melissophyllum, Mentha spp., Mentzelia cordifolia,Menyanthes trifoliata, Mesembryanthemum crystallinum, Mespilusgermanica, Mikania amara, Mitchella repens, Momordica spp., Monardaspp., Morinda spp., Moringa oleifera, Moms spp., Murraya koenigii, Musax paradisiaca, Myrciaria dubia, Myrica gale, Myristica fragrans,Myroxylon spp., Myrtus communis, Nardostachys jatamansi, Nasturtiumofficinale, Nelumbo nucifera, Nepeta spp., Nephelium lappaceum, Nigellasativa, Ocimum spp., Oenanthe aquatica, Oenothera biennis, Olea spp.,Ononis spp., Onopordon acanthium, Ophioglossum vulgatum, Ophiopogonjaponicus, Opopanax chironius, Opuntia ficus-indica, Orchis mascula,Origanum spp., Orthosiphon spp., Oryza sativa, Oxalis acetosella,Pachira spp., Padus avium, Paeonia spp., Palmaria palmata, Panax spp.,Panicum miliaceum, Panzerina lanata, Papaver rhoeas, Parietariaofficinalis, Parmelia saxatilis, Parthenium hysterophorus,Parthenocissus tricuspidata, Passiflora incarnata, Pastinaca sativa,Paullinia cupana, Pedalium murex, Pelargonium spp., Perilla frutescens,Persea americana, Persicaria spp., Petiveria alliacea, Petroselinumcrispum, Peucedanum ostruthium, Peumus boldus, Phaseolus vulgaris,Phellodendron amurense, Phillyrea latifolia, Phlebodium aureum, Phoenixdactylifera, Photinia melanocarpa, Phyla scaberrima, Phyllanthus spp.,Phymatolithon calcareum, Physalis spp., Picea abies, Picramniaantidesma, Pimenta spp., Pimpinella spp., Pinus spp., Piper spp.,Pistacia spp., Pisum sativum, Plantago spp., Platycodon grandiflorus,Plectranthus barbatus, Pogostemon cablin, Polygala spp., Polygonatumodoratum, Polygonum aviculare, Populus spp., Porphyra umbilicalis,Portulaca oleracea, Potentilla spp., Prangos pabularia, Primula spp.,Protium spp., Prunella vulgaris, Prunus spp., Psidium spp., Pterocarpusspp., Pueraria spp., Pulmonaria officinalis, Punica granatum, Pyrolarotundifolia, Pyropia tenera, Pyrus communis, Quercus spp., Quillaj asaponaria, Raphanus spp., Raphia farinifera, Rehmannia glutinosa,Rhamnus spp., Rheum spp., Rhodiola crenulata, Rhus spp., Ribes spp.,Robinia pseudoacacia, Roccella phycopsis, Rosa spp., Rosmarinusofficinalis, Rubia cordifolia, Rubus spp., Rumex spp., Ruscus spp.,Sabatia angularis, Saccharina latissima, Saccharum officinarum, Salixspp., Salvia spp., Sambucus spp., Sanguisorba spp., Sanicula elata,Santalum album, Santolina chamaecyparissus, Saponaria officinalis,Saposhnikovia divaricata, Sarcopoterium spinosum, Sargassum fusiforme,Sarracenia purpurea, Satureja spp., Saussurea costus, Schinus molle,Schisandra chinensis, Scorzonera hispanica, Scrophularia ningpoensis,Scutellaria spp., Secale cereale, Sedum spp., Selenicereus grandiflorus,Sempervivum tectorum, Senna spp., Sequoiadendron giganteum, Serenoarepens, Sesamum indicum, Seseli tortuosum, Sideritis syriaca,Sigesbeckia orientalis, Silaum silaus, Silybum marianum, Simaroubaamara, Simmondsia chinensis, Siraitia grosvenorii, Sisymbriumofficinale, Sium latifolium, Smilax spp., Solanum spp., Solidagovirgaurea, Sorbus aucuparia, Sorghum bicolor, Spatholobus suberectus,Spergularia rubra, Spinacia oleracea, Spirulina spp., Stachysofficinalis spp., Stellaria media, Stemmacantha carthamoides,Styphnolobium japonicum, Styrax spp., Symplocarpus foetidus, Syringavulgaris, Syzygium spp., Tagetes spp., Tamarindus indica, Tamarixgallica, Tanacetum spp., Taraxacum officinale, Terminalia spp.,Thalictrum flavum, Theobroma cacao, Thlaspi arvense, Thymus spp., Tiliaspp., Trachyspermum ammi, Tragopogon porrifolius, Tribulus terrestris,Trichilia catigua, Trichosanthes kirilowii, Tridax procumbens, Trifoliumspp., Trigonella spp., Trillium erectum, Triticum spp., Tropaeolum spp.,Tsuga Canadensis, Turnera diffusa, Ulmus spp., Ulva lactuca, Uncariaspp., Undaria pinnatifida, Urtica spp., Usnea spp., Vaccinium spp.,Valeriana spp., Valerianella locusta, Vanilla planifolia, Veratrumviride, Verbascum spp., Verbena officinalis, Veronica spp., Viburnumspp., Vicia spp., Vigna angularis, Viola spp., Viscum album, Vitex spp.,Vitis vinifera, Withania somnifera, Xeranthemum annuum, Yucca spp.,Zanthoxylum spp., Zea mays, Zingiber officinale, Ziziphus jujube.

In a further embodiment, the invention relates to a fiber-web comprisingfrom about 5% to about 100% (w/w), preferably at least about 10%, atleast about 20%, at least about 30%, at least about 40%, at least about50%, at least about 60%, at least about 70%, at least about 80%, atleast about 90%, or about 100%, fibers of herbs, medicinal plants, tea,vegetables and/or spices. In one embodiment, the fiber-web furthercomprises cellulosic and/or synthetic fibers, and fibers of herbs,medicinal plants, tea, vegetables and/or spices in a ratio of forexample: 40/60 (w/w), 50/50 (w/w), 60/40 (w/w), 70/30 (w/w) or 20/80(w/w). In another embodiment of the invention, the fiber-web of thepresent invention is obtainable by the method disclosed herein, namelyas an intermediate product in step d) of the said method.

The invention further relates to a composition for making a beverage,obtainable by the method of the present invention disclosed herein.

The invention also includes the use of the composition of the inventionfor making a beverage, or for culinary use or use in cooking,respectively, i.e. as a herb and spice mixture.

Also included is a beverage obtainable by contacting water or anotherliquid with the composition of the invention.

In one embodiment of the invention, the fiber-web comprises from about5% to about 100% (w/w), preferably at least about 10%, at least about20%, at least about 30%, at least about 40%, at least about 50%, atleast about 60%, at least about 70%, at least about 80%, at least about90%, or about 100%, fibers of herbs, medicinal plants, tea, vegetablesand/or spices. For certain applications, the fiber-web may furthercomprise synthetic and/or natural fibers such as cellulosic fibers. In aparticular embodiment, the fiber-web comprises fibers of (i) herbs,medicinal plants, and/or tea, vegetables and/or spices and (ii)synthetic and/or natural fibers such as cellulosic fibers in a ratio of40/60 (w/w), 60/40 (w/w) or 80/20 (w/w).

The invention further relates to a fiber-web, obtainable by the methodof the invention, namely in step d).

In some embodiments of the invention, the fiber-web further comprises acoating or impregnation with soluble portion (plant extract) of herbs,medicinal plants, tea, vegetables and/or spices.

The coating or impregnation is obtained by various methods known to theskilled person, such as applying to or treating the fiber-web orsheet-like structure with a plant extract, such as in a bath or byspecial application means, such as sprayers. In addition, various otheringredients, such as flavor or color treatments, can also be applied tothe web. If applied with the soluble portion and/or other ingredients,the fibrous sheet material can, in some embodiments, then be driedusing, for example, a tunnel dryer, to provide a sheet having a typicalmoisture content of less than 20% by weight, and particularly from about9% to about 14% by weight.

The invention thus also relates to an impregnated or coated fiber-web,obtainable by the method of the invention, namely in step g).

According to a further embodiment, the fiber-web of the inventionfurther comprises a coating or an impregnation with the soluble portion(plant extract) of said herbs, medicinal plants, tea, vegetables and/orspices. In another embodiment of the invention, the fiber-web of thepresent invention is obtainable by the method disclosed herein, namelyas the end product in step g) of said method.

The products of the invention enable a more efficient extraction (up toabout 100% solubles can be extracted from the plant) in the sense thatmore solubles can be released than natural plant ingredients for a givenweight of material. The products also provide a faster extraction (thanwith a conventional extraction made from the vegetal material in itsnatural non converted form). Specifically, the compositions of theinvention have improved efficiency, e.g. in boiling water or innon-heated water or water at room temperature.

The process for making the compositions of the invention also allows forspecifically adjusting the final composition of the products, such as toremove from the soluble or the non-soluble portion(s) for exampleforeign matters, components altering taste and/or odor, or caffeine,pesticides, heavy metals, mycotoxins, toxicants and allergenic moleculessuch as coumarin, farnesol, geraniol, limonene, linalol, safrole,methyleugenol, or by adding to the soluble or the non-soluble portion(s)for example desirable additives, such as sweeteners, sugars, flavors,casings, vitamins, colorants, minerals, taste enhancers.

In another embodiment, the soluble portion in the reconstituted materialof the invention can be precisely adjusted (decreased as compared tostandard level, at standard level, or increased as compared to standardlevel). A key benefit is that the level of ingredients in thereconstituted material can be precisely increased to a level higher thanin the original natural form, thus allowing for products with a higherconcentration of desired substances. The adjustment of ingredients canalso guarantee a consistent, standardized level of delivered ingredientsto compensate natural variations of substances, i.e. active ingredients,in plants.

Preferably, the method of the invention also allows for reduction ofundesired compounds from the material, such as to selectively removeundesired components (natural ingredients, pesticides, impurities or thelike). For example, it is possible to remove components from either thesoluble portion (plant extract) or from the non-soluble portion (solidplant particles) or both by liquid-liquid extraction, physicaladsorption, centrifugation, chromatography, crystallization,decantation, by use of a demister, drying, distillation,electrophoresis, elutriation, evaporation, solid phase or liquid-liquidextraction, flotation, flocculation, filtration (for example usingmembranes), vapor-liquid separation, and/or sublimation and other meanswell known to the skilled person, preferably before applying the plantextract to the base web.

In connection with adding ingredients, extracts of different sources andorigins, flavors, coloring agents or the like may be used, such asclorophyll, anthocyans, caramel, caroteinoids. For example, when usingtea or herbs it is possible to include L-menthol at various quantities(such as 6% or 15%) in the finished product. Products so obtained have adistinctive taste and aroma of menthol.

The present invention also allows to blend various plants and herbs. Inone example, instead of using single plants, such as tea or mint leaves,tea may be replaced by a mixture of, for example, 50% tea and 50% mintleaves (w/w); 50% verbena and 50% mint (w/w); 30% cinnamon and 30% teaand 10% licorice and 10% chamomile and 10% red vine and 10% roobois(w/w); and many other combinations.

The combination of different plant materials through the reconstitutionprocess into a single fiber web impregnated with extracts from differentplants (the same plant or blends) offers new taste experiences andadditive or synergistic effects. For example, it is known thatcombinations of certain plant extracts or combinations of certain plantingredients have additive or synergistic effects, such as, for example,a mixture of hops and valerian extracts for use in treating insomnia andvigilance (Blumenthal and al., J. Herbal Medicine, expanded Commission Emonographs, American Botanical Council, Austin, 2000, 394-400), ormixtures of oregano and cranberry extracts for use in treating H. pyloriinfections (Lin et al., Appl. Environ. Microbiol. December 2005, vol.71, no. 12, 8558-8564), or different mixtures of extracts of S.baicalensis, D. morifolium, G. uralensis and R. rubescens tested fortheir additive or synergistic effect in prostate cancer cell lines(Adams et al., Evid Based Complement Alternat Med. 2006 March; 3(1):117-124).

It has been found that some beverages are particularly less astringentand bitter when prepared from the reconstituted plant material orproduct of the invention as compared to original material from which thereconstituted plant material or product of the invention was prepared.This is, for example, the case for green tea, which is less astringentand bitter when made from a reconstituted green tea product according tothe invention as compared to a conventional infusion of green tea.

The production method also provides for reducing microbiological load ofthe final products because of the high temperatures during thepapermaking process.

The products of the invention provide a light material having a smallsurface, which allows economic packaging/shipping. For the consumer, theproducts of the invention are easy to transport and easy to use.Specifically, it has been found that the products of the invention areeasily extractable even in cold water. This has particular advantagesfor consumers in cases where no heating or electricity is available forpreparing hot water.

The products of the invention can also be used as wrapping/packagingmaterial which can be later on consumed.

The products are further available in all shapes, dimensions andformats, such as leaves, sticks, discs and the like, and can becustomized with a logo.

In sum, the reconstituted plant products of the invention provideseveral benefits and advantages, such as

-   -   the provision of products with higher extraction yield and        extraction speed;    -   the provision of a preferably dispersible and biodegradable        product;    -   the ability to adjust the content of active ingredients (such as        polyphenols, essential oils and the like) to provide a        consistent composition;    -   the ability to adjust (reduce) the content of undesired        constituents (such as pesticides, caffeine and the like);    -   the ability to provide new sensory characteristics (such as        adjusting intensity of flavor, mixture of various plants and the        like); and    -   reduction of the bacterial load during the manufacturing        process.

The following examples further describe and demonstrate embodiments thatare within the scope of the present invention. The examples are givensolely for the purpose of illustration, and are not to be construed aslimitations of the present invention since many variations thereof arepossible without departing from its spirit and scope.

EXAMPLES Example 1

Method of Making the Reconstituted Plant Product

As raw material a black tea plant was used. The plant was mixed withwater with a plant/water ratio of 1 to 5 by weight and the mixture washeated at 85° C. for 20 minutes. Subsequently, the aqueous portion wasseparated from the fibrous portion by an extraction step in a hydraulicpress. Afterwards, the fibrous residue was again heated at 85° C. for 10minutes with a plant/water ratio of 1 to 5 by weight. Again, the aqueousportion was separated from the fibrous portion by an extraction step ina hydraulic press. Then, the samples were refined in a Valley beater at1.4% consistency for 10 minutes. As a next step, cellulosic fibers andin particular (a blend of abaca, hardwood and softwood pulps, with therespective ratios: 60/10/30) were added to the fibrous residue with afibrous residue/woodpulp ratio of 5 to 1 in weight and hand sheets weremade. The aqueous portion, which was separated by pressing, wasconcentrated in an evaporator to a solid concentration of 50%.

The concentrated aqueous portion was coated on the hand sheets on amanual size-press. The soluble level is typically between 27 and 37% indry finished product. The soluble level of the reconstituted plant wasapprox. 27%, which is the soluble content of conventional plant used asthe starting material of the experiment. The coated hand sheets weredried on a plate dryer. The obtained reconstructed plant product had theform of discs.

Comparison of Reconstituted Plant Product Versus Conventional Plant

The obtained reconstructed plant was tested for its properties. Also, aconventional black tea plant was packed into a conventional cellulosicbag for preparing a comparison infusion. For determining the propertiesthe optical density of the solutions were measured at 274 nm. Both thereconstructed plant and the conventional plant were inserted into hotwater (90° C.). Same weights of plant material and identicalexperimental conditions were used. A beaker was filled with 200 ml water(ref. Cristaline) and was heated at 90° C. At the starting point of theexperiment, i.e. T=0, the heating was stopped and the bag withconventional black tea was immersed into water. To homogenize thecontent of the beaker during the entire experiment, a rotary magnet wasused.

In steps of 30 seconds six samples of the water were taken. Then, theoptical density of the sample was determined using a spectrophotometerat the wavelength of 274 nm. For the reference test a sample of clearwater (Cristaline) heated at 90° C. was used. Then the same procedurewas repeated with the bag comprising the reconstituted plant productaccording to the invention.

As can be taken from FIG. 2 , the optical density measured after 3minutes of extraction for the reconstituted plant product was 0.69,whereas for the conventional plant 0.63 was measured. Hence, the productaccording to the invention provided a higher extraction rate of solublesas compared to a conventional plant product. In particular, theextraction ratio in this test was +10% as compared to the conventionalbag. The reconstituted plant enabled a more efficient extraction (up toabout 100% solubles were extracted from the plant). In other words,using the same amount of material, more solubles could be released fromthe reconstituted plant product according to the invention than from theconventional plant product in a standard cellulosic bag.

Similar results were obtained with different extraction times, or whenthe reconstituted plant was compared to natural black tea in loose form,i.e. without a cellulosic bag.

The above findings show the improved properties of the reconstructedplant. These findings, namely the improved substance release, areequally meaningful for other applications, e.g. with a different solventor without a solvent.

Example 2

The reconstructed plant product obtained according to the method asexplained in example 1 was used to determine a first extraction rate. Onthe other hand, natural black tea in a conventional cellulosic bag wasused to determine a second extraction rate. The first and secondextraction rates are representative of the speed soluble substances canbe released from the plant products. The result is graphically shown inFIG. 3 .

Like in example 1, the reconstructed plant was immersed into water at90° C. and the optical density was measured over time. Likewise, theconventional plant product was immersed into water at 90° C. The moresolubles are released from the plant, the higher the optical density ofthe respective water will be. As shown in FIG. 3 , the optical densityof the water with the reconstituted plant (dashed line) changes fasterthan the water with the conventional plant (continuous line). An opticaldensity of 0.6 was reached by the reconstituted plant within 20 seconds.In contrast, the same optical density was reached by the conventionalplant only after about 2 minutes.

This again shows that the reconstituted plant provides improvedproperties as regards the rate substances can be released from the plantproduct.

Similar results were obtained when reconstituted plant product wascompared to natural black tea in loose form.

Example 3

In this example exactly the same setup was used as in example 2, onlythe water was at room temperature, i.e. 20° C.

As shown in FIG. 4 , the optical density of the water with thereconstituted plant (dashed line) changes faster than the water with theconventional plant (continuous line). The water with the reconstitutedplant reached an optical density of 0.3 within about 30 seconds and anoptical density of 0.6 within about 2 minutes. In contrast, theconventional plant in a bag required about 6 times longer to provide theoptical density of 0.3. Hence, the reconstituted plant product providesfaster extraction than conventional plant in bags. Similar results wereobtained when reconstituted plant was compared to natural black tea inloose form.

Example 4

This example shall demonstrate the adjustability (higher or lower than astandard) of the amount of solubles and active ingredients present onthe reconstituted plant product. The soluble content was measured bydetermining the weight of a given sample before and after extraction.

Black tea was used to produce a reconstituted plant product according tothe method of example 1. As control, a conventional black tea was usedcontaining solubles in an amount of 26% (w/w).

By adjusting the coating ratio, the amount of solubles was adjusted inthree different runs to 5% (w/w; decreased level), to 26% (w/w; standardlevel) and to 50% (w/w; increased level).

Due to the adjustability of the reconstituted product according to theinvention it is possible to provide a consistent, standardized deliverylevel of soluble/active ingredients as compared to the natural productsthat generally show an inherent variability.

Example 5

In this example different reconstituted plant products were manufacturedaccording to the method of example 1 and tested.

Sample 1 (Original Plant in Loose Form)

For natural black tea in loose form the amount of solubles wasdetermined to be around 30%.

Sample 2 (Original Plant in Cellulosic Bag)

For natural black tea, i.e. the same as in Sample 1, in a conventionaldouble chamber cellulosic bag the amount of solubles was determined tobe around 30%.

Sample 3 (Reconstituted Plant with Standard Amount of Solubles)

A reconstituted plant product according to the invention was made fromblack tea. The reconstituted plant product was in the form of disks andhad a standard dry basis weight, i.e. 100 gsm. The amount of solubles,which corresponds to the coating ratio for the reconstituted sample, wasthe same as of the natural plant, i.e. 30%.

Sample 4 (Reconstituted Plant with Decreased Amount of Solubles)

A reconstituted plant product according to the invention was made fromblack tea. The reconstituted plant product was in the form of disks andhad a standard dry basis weight. The amount of solubles was 20% and thusdecreased in comparison with the standard of 30%.

Sample 5 (Reconstituted Plant with Increased Amount of Solubles)

A reconstituted plant product according to the invention was made fromblack tea. The reconstituted plant product was in the form of disks andhad a standard dry basis weight. The amount of solubles was 50% and thusincreased in comparison with the standard of 30%.

Sample 6 (Reconstituted Plant with Decreased Dry Basis Weight)

A reconstituted plant product according to the invention was made fromblack tea. The reconstituted plant product was in the form of disks andhad a decreased dry basis weight of 60 gsm as compared to the standarddry basis weight of 100 gsm. The amount of solubles was the same as ofthe natural plant, i.e. 30%.

A comparison of the properties of the samples, in particular acomparison of sample 3 with samples 1 and 2; sample 3 with samples 4 and5; and sample 3 with sample 6, confirmed the findings of the foregoingexamples. That is, the reconstituted plant provides a better ratio ofextraction and faster extraction and allows to adjust the amount ofsolubles/active ingredients released.

Example 6

Method of Making a Bag Comprising Reconstituted Plant Product

Black tea was mixed with water with a plant/water ratio of 1 to 5 byweight and the mixture was heated at 85° C. for 20 minutes.Subsequently, the aqueous portion was separated from the fibrous portionby an extraction step in a hydraulic press. Afterwards, the fibrousresidue was again heated at 85° C. for 10 minutes with a plant/waterratio of 1 to 5 by weight. Again, the aqueous portion was separated fromthe fibrous portion by an extraction step in a hydraulic press. Then,the samples were refined in a Valley beater at 1.4% consistency for 10minutes. As a next step, cellulosic fibers (a blend of abaca, hardwoodand softwood pulps, with the respective ratios: 60/10/30) were added tothe plant fibrous residue at various levels in order to prepare thedifferent samples and make hand sheets. Hand sheets were later dried ona plate dryer.

The following ratios of plant/cellulosic fibers have been used forproducing a bag:

-   -   first sample: 40/60 (w/w);    -   second sample 60/40 (w/w);    -   third sample 80/20 (w/w).

No plant extract was located on the bags but the sample bags were filledwith conventional black tea.

Comparison of Bag Comprising Reconstituted Plant Product VersusConventional Cellulosic Bag

A bag produced according to the above method was compared to aconventional cellulosic bag containing the same amount of black tea.

The outcome was similar to examples 1 and 2. As can be taken from FIG. 5, the extraction performance of the sample corresponding to the 80/20ratio (first sample) matched with the extraction performance ofconventional cellulosic bags as measured by optical density.

Example 7

Plant extract from the extracting step was used to impregnate the fiberweb of example 6 to obtain impregnated bags with an amount of plantextract from 5% to 50% of the total weight. The bags were filled withblack tea.

The measurements of the extraction performance of the produced bags ascompared to conventional cellulosic bags containing the same amount ofplant revealed a similar outcome as examples 1 and 2. That is, from thebags according to the invention more solubles were released, andextraction rates were higher due to the additional release of substancesfrom the coating (plant extract), in addition to natural extractioncoming from the black tea which was contained in the bag.

One sample bag according to the invention was impregnated with plantextract as described above. Using water at 90° C., the product released35% (w/w) plant solubles into the water.

Example 8

The following products were produced:

-   -   1) A product in the form of a plant bag was produced with about        5% solubles (w/w) and a dry basis weight of approx. 120 g/m²        (w/w);    -   2) A product in the form of a plant bag was produced with about        5% solubles (w/w) and a dry basis weight of approx. 60 g/m²        (w/w).

Both products were not filled with plant. Both bags have the samecontact surface but have a different weight. The second plant bag havinga dry basis weight of approx. 60 g/m² (w/w) is half the weight of thefirst plant bag having a dry basis weight of approx. 120 g/m² (w/w).

As can be taken from FIG. 6 , the first product comprising a dry basisweight of approx. 120 g/m² (w/w) releases more substances in shortertime as the second product comprising a lower dry basis weight ofapprox. 60 g/m² (w/w). In other words, release of solubles can be drivenby the basis weight of the finished product.

Example 9

Example 1 described above was repeated with the additional use of a wetstrength agent (here: cationic polyamide amine resin), in order toreduce potential degradation of some of the reconstituted material inwater. The wet strength agent was added to the fibrous portion.

A tea product was made according to the following method: A black teawas initially heated at 85° C. for 20 minutes with a tea/water ratio of1 to 5 by weight. This was followed by an extraction step in a hydraulicpress to separate the aqueous portion from the tea fiber portion. Therecovered tea fiber portion was again heated at 85° C. for 10 minuteswith a tea/water ratio of 1 to 5 by weight. After an additionalextraction (by pressing), the fibrous portion was then refined in aValley beater at 1.4% consistency for 10 minutes. After refining,cellulosic fibers (a blend of abaca, hardwood and softwood pulps, withthe respective ratios: 60/10/30) were added to the tea fibrous residuewith a tea fiber/woodpulp ratio of 5 to 1 in weight and a wet strengthagent was then added to the fibrous portion at a level of 5% w/w inorder to make hand sheets. The aqueous portion was concentrated in anevaporator to a solid concentration of 50% and then coated on a handsheet on a manual size-press. The soluble level is typically between 27and 37% in dry finished product. In this example, soluble level of thereconstituted tea was approx. 27%, which is the soluble content ofconventional tea used as the starting material of the experiment. Thecoated hand sheets were dried on a plate dryer. Infusion trials were runin hot water (approx. 90° C.) and product with wet strength agent showedless degradability into water than same material without agent.

FIG. 7 shows reconstituted tea in one example without the use of a wetstrength agent after 3 mins of infusion. The photograph shows thatmaterial is degraded.

FIG. 8 shows reconstituted tea in this example with the use of a wetstrength agent after 3 mins of infusion. The photograph shows that thematerial is substantially undegraded.

Example 10

In order to determine the effect of reconstituted plant soluble contentand the dry basis weights on the infusion profile, a tea product wasmade according to the following method: A black tea was initially heatedat 85° C. for 20 minutes with a tea/water ratio of 1 to 5 by weight.This was followed by an extraction step in a hydraulic press to separatethe aqueous portion from the tea fiber portion. The recovered tea fiberportion was again heated at 85° C. for 10 minutes with a tea/water ratioof 1 to 5 by weight. After an additional extraction (by pressing), thefibrous portion was then refined in a Valley beater at 1.4% consistencyfor 10 minutes. After refining, cellulosic fibers (a blend of abaca,hardwood and softwood pulps, with the respective ratios: 60/10/30) wereadded to the tea fibrous residue with a tea fiber/woodpulp ratio of 5 to1 in weight and a wet strength agent was then added to the fibrousportion at a level of 5% w/w in order to make hand sheets. The aqueousportion was concentrated in an evaporator to a solid concentration of50% and then coated on a hand sheet on a manual size-press. The solublelevel is typically between 27 and 37% in dry finished product. In thisexample, the following products were prepared:

Product A: soluble level of the reconstituted tea was 22%, which is thesoluble content of conventional tea used as the starting material of theexperiment. Dry basis weight of the material was 70 grs per m² (drybasis);

Product C: soluble level of the reconstituted tea was 22%, which is thesoluble content of conventional tea used as the starting material of theexperiment. Dry basis weight of this material was 170 grs per m² (drybasis) which is 143% higher than A;

Product D: soluble level of the reconstituted tea was 38% which is 73%higher than A. Dry basis weight of D material was 170 grs per m² (drybasis).

The coated hand sheets were dried on a plate dryer.

The products (A, C and D) obtained in this example were tested for theirproperties including sensory properties, their propensity to releaseplant extract by preparing tea and compared. Both products were used tomake tea, and the optical density of the solution (tea) was measured at274 nm. For all samples, the total infusion time in hot water (90° C.)was 5 minutes. Same weights of tea material (2.5 grs) and identicalexperimental conditions were used: a beaker containing 500 ml water washeated at 90° C. At T=0, ie. upon start of the experiment, heating wasstopped and a tea strip was immersed into water. A rotary magnet wasused to homogenize the content of the beaker during the entireexperiment.

Samples of water were taken regularly and up to 5 minutes. Then, theoptical density of the sample was determined using a spectrophotometerat the wavelength of 274 nm (maximum absorption of caffeine). Thereference/blank test was run with a sample of clear water heated at 90°C.

The result is graphically shown in FIGS. 9 and 10 .

FIG. 9 : Reconstituted tea (D—high soluble content) shows a higherinfusion level of tea solubles than C (standard soluble level). In orderto reach an infusion level of 8.3 (expressed by 10× optical density at274 nm), it takes 300 sec with sample C whereas only 40 sec are neededfor D material (87% faster). Sensory evaluation performed by panel groupalso showed a stronger tea flavor and taste with D than with C. Thisdemonstrates that product taste can be adjusted thanks to solublecontent of reconstituted tea material.

FIG. 10 shows that reconstituted tea A with a lower basis weight shows afaster infusion level of tea solubles than C. Figures show that infusionrate of 8.3 (expressed by 10× optical density at 274 nm) is reached in120 sec for A sample whereas 300 sec are needed for C. Infusion with Ais 60% faster than with C. Actually, a lower basis weight for a givenweight of material entails a more important contact surface which, atthe end, improves infusion kinetics.

Example 11

In order to determine the effect of the reconstitution process on thegreen tea product sensory profile, a tea product was made according tothe following method: a green tea (Sencha from China) was initiallyheated at 85° C. for 20 minutes with a tea/water ratio of 1 to 5 byweight. This was followed by an extraction step in a hydraulic press toseparate the aqueous portion from the tea fiber portion. The recoveredtea fiber portion was again heated at 85° C. for 10 minutes with atea/water ratio of 1 to 5 by weight. After an additional extraction (bypressing), the fibrous portion was then refined in a Valley beater at1.4% consistency for 10 minutes. After refining, cellulosic fibers (ablend of abaca, hardwood and softwood pulps, with the respective ratios:60/10/30) were added to the tea fibrous residue with a teafiber/woodpulp ratio of 5 to 1 in weight and a wet strength agent wasthen added to the fibrous portion at a level of 5% w/w in order to makehand sheets. The aqueous portion was concentrated in an evaporator to asolid concentration of 50% and then coated on a hand sheet on a manualsize-press. In this example, the product was produced at 36% extractcontent, which is the soluble content of the starting material of theexperiment. The coated hand sheets were dried on a plate dryer.

The product obtained in this example was tested for its sensoryproperties and compared to natural tea material used for the experimentas described above. Both products were used to make tea. For allsamples, the total infusion time in hot water (90° C.) was 5 minutes.Same weights of tea material (2 grs) and identical experimentalconditions were used: a beaker containing 200 ml water was heated at 90°C. and tea materials were immersed into water. Then, after 5 minutes,sensory profile of both products was performed. The result isgraphically shown in FIG. 11 .

The experiment shows that the odor, color and taste are higher in thereconstituted tea than in the natural material. However, astringency andbitterness are significantly lower in the reconstituted tea than naturalmaterial.

Example 12

Reconstitution of Rooibos Leaves

A reconstituted product was made according to the following method:Rooibos (Aspalathus linearis) was initially heated at 85° C. for 20minutes with a rooibos/water ratio of 1 to 5 by weight. This wasfollowed by an extraction step in a hydraulic press to separate theaqueous portion from the rooibos fiber portion. The recovered rooibosfiber portion was again heated at 85° C. for 10 minutes with arooibos/water ratio of 1 to 5 by weight. After an additional extraction(by pressing), the fibrous portion was then refined in a Valley beaterat 1.4% consistency for 10 minutes. After refining, cellulosic fibers (ablend of abaca, hardwood and softwood pulps, with the respective ratios:60/10/30) were added to the rooibos fibrous residue with a rooibosfiber/woodpulp ratio of 5 to 1 in weight and a wet strength agent wasthen added to the fibrous portion at a level of 5% w/w in order to makehand sheets. The aqueous portion was concentrated in an evaporator to asolid concentration of 50% and then coated on a hand sheet on a manualsize-press. In this example, the product was produced at 22% extractcontent, which is the soluble content of the starting material of theexperiment. The coated hand sheets were dried on a plate dryer.

The product obtained in this example was tested for its sensoryproperties and compared to natural rooibos material used for theexperiment as described above. Both products were used to make a rooibosbeverage. For all samples, the total infusion time in hot water (90° C.)was 5 minutes. Same weights of rooibos material (2 grs) and identicalexperimental conditions were used: a beaker containing 200 ml water washeated at 90° C. and rooibos materials were immersed into water. Then,after 5 minutes, sensory profile of both products was performed. Theresult is graphically shown in FIG. 12 .

The experiment demonstrates that reconstituted rooibos tea shows astronger taste than original material. Moreover, color is stronger.

The reconstituted rooibos obtained in this example and its originalmaterial were tested for their properties in preparing infusion andcompared. Both products were used to make infusion, and the opticaldensity of the solution was measured at 450 nm. For all samples, thetotal infusion time in hot water (90° C.) was 5 minutes. Same weights ofmaterials (2.5 grs) and identical experimental conditions were used: abeaker containing 500 ml water was heated at 90° C. At T=0, ie. uponstart of the experiment, heating was stopped and a reconstituted rooibosstrip was immersed into water. A rotary magnet was used to homogenizethe content of the beaker during the entire experiment.

Samples of water were taken regularly and up to 5 minutes. Then, theoptical density of the sample was determined using a spectrophotometerat the wavelength of 450 nm (maximum absorption of lutein). Thereference/blank test was run with a sample of clear water heated at 90°C.

The infusion performance for reconstituted Rooibos material isgraphically shown in FIG. 13 . Infusions of rooibos products arecomparable. However, it is demonstrated that reconstituted rooibosoffers a more complete extraction. After 5 mins infusion, opticaldensity of liquor made of reconstituted rooibos is 1.1 compared 0.9 fororiginal material (+22%).

Example 13

Reconstitution of Thyme Leaves

A reconstituted product was made according to the following method:Thyme (Thymus vulgaris) was initially heated at 85° C. for 20 minuteswith a thyme/water ratio of 1 to 5 by weight. This was followed by anextraction step in a hydraulic press to separate the aqueous portionfrom the thyme fiber portion. The recovered thyme fiber portion wasagain heated at 85° C. for 10 minutes with a thyme/water ratio of 1 to 5by weight. After an additional extraction (by pressing), the fibrousportion was then refined in a Valley beater at 1.4% consistency for 10minutes. After refining, cellulosic fibers (a blend of abaca, hardwoodand softwood pulps, with the respective ratios: 60/10/30) were added tothe thyme fibrous residue with a thyme fiber/woodpulp ratio of 5 to 1 inweight and a wet strength agent was then added to the fibrous portion ata level of 5% w/w in order to make hand sheets. The aqueous portion wasconcentrated in an evaporator to a solid concentration of 50% and thencoated on a hand sheet on a manual size-press. In this example, theproduct was produced at 30% extract content, which is the solublecontent of the starting material of the experiment. The coated handsheets were dried on a plate dryer. The product obtained in this examplewas tested for its sensory properties and compared to natural thymematerial used for the experiment as described above. Both products wereused to make a thyme beverage. For all samples, the total infusion timein hot water (90° C.) was 5 minutes. Same weights of thyme material (2grs) and identical experimental conditions were used: a beakercontaining 200 ml water was heated at 90° C. and thyme materials wereimmersed into water. Then, after 5 minutes, sensory profile of bothproducts was performed. The result is graphically shown in FIG. 14 .

The experiment shows that that the color is rather yellow for thereconstituted thyme and rather green for the naturel leaves. Global odorand herbal notes are higher for the natural thyme. However, the taste ofthyme is higher in the reconstituted material.

The reconstituted thyme obtained in this example and its originalmaterial were tested for their properties in preparing infusion andcompared. Both products were used to make infusion, and the opticaldensity of the solution was measured at 326 nm. For all samples, thetotal infusion time in hot water (90° C.) was 5 minutes. Same weights ofmaterials (2.5 grs) and identical experimental conditions were used: abeaker containing 500 ml water was heated at 90° C. At T=0, ie. uponstart of the experiment, heating was stopped and a reconstituted thymestrip was immersed into water. A rotary magnet was used to homogenizethe content of the beaker during the entire experiment.

Samples of water were taken regularly and up to 5 minutes. Then, theoptical density of the sample was determined using a spectrophotometerat the wavelength of 326 nm (maximum absorption of rosmarinic acid). Thereference/blank test was run with a sample of clear water heated at 90°C. The result is shown in FIG. 15 .

FIG. 15 shows that reconstituted thyme infusion occurs very quickly.After 90 sec infusion, optical density of original material is 2.3whereas liquor from reconstituted thyme optical density is 5.3 which is130% higher.

Example 14

Reconstitution of Thyme and Black Tea leaves

A reconstituted product was made according to the following method:Thyme (Thymus vulgaris) and black tea (Camelia sinensis) natural leaveswere initially blended with a ratio of 50/50 and aforementioned blendwas heated at 85° C. for 20 minutes with a blend/water ratio of 1 to 5by weight. This was followed by an extraction step in a hydraulic pressto separate the aqueous portion from the blend fiber portion. Therecovered blend fiber portion was again heated at 85° C. for 10 minuteswith a blend/water ratio of 1 to 5 by weight. After an additionalextraction (by pressing), the fibrous portion was then refined in aValley beater at 1.4% consistency for 10 minutes. After refining,cellulosic fibers (a blend of abaca, hardwood and softwood pulps, withthe respective ratios: 60/10/30) were added to the blend fibrous residuewith a blend fiber/wood pulp ratio of 5 to 1 in weight and a wetstrength agent was then added to the fibrous portion at a level of 5%w/w in order to make hand sheets. The aqueous portion was concentratedin an evaporator to a solid concentration of 50% and then coated on ahand sheet on a manual size-press. In this example, the product wasproduced at 25% extract content, which is the balanced soluble contentof the materials of the experiment. The coated hand sheets were dried ona plate dryer.

The product obtained in this example was tested for its sensoryproperties and compared to natural blend material used for theexperiment as described above. Both products were used to make theinfusion. For all samples, the total infusion time in hot water (90° C.)was 5 minutes. Same weights of material (2 grs) and identicalexperimental conditions were used: a beaker containing 200 ml water washeated at 90° C. and blend was immersed into water. Then, after 5minutes, sensory profile of both products was performed. The result isgraphically shown in FIG. 16 .

The experiment shows that color and overall taste are higher in thereconstituted leaves. Also, thyme and black tea notes are higher. Butthe astringency of the product is lower in the reconstituted material.

Example 15

Reconstitution of Thyme and Laurel Leaves (“Bouquet Garni”)

A reconstituted product was made according to the following method:Thyme (Thymus vulgaris) and Laurel (Laurus nobilis) natural leaves wereinitially blended with a ratio of 50/50 and aforementioned blend washeated at 85° C. for 20 minutes with a blend/water ratio of 1 to 5 byweight. This was followed by an extraction step in a hydraulic press toseparate the aqueous portion from the blend fiber portion. The recoveredblend fiber portion was again heated at 85° C. for 10 minutes with atea/water ratio of 1 to 5 by weight. After an additional extraction (bypressing), the fibrous portion was then refined in a Valley beater at1.4% consistency for 10 minutes. After refining, cellulosic fibers (ablend of abaca, hardwood and softwood pulps, with the respective ratios:60/10/30) were added to the blend fibrous residue with a blendfiber/woodpulp ratio of 5 to 1 in weight and a wet strength agent wasthen added to the fibrous portion at a level of 5% w/w in order to makehand sheets. The aqueous portion was concentrated in an evaporator to asolid concentration of 50% and then coated on a hand sheet on a manualsize-press. In this example, the product was produced at 34% extractcontent which is the balanced soluble content of the materials of theexperiment. The coated hand sheets were dried on a plate dryer.

The product obtained in this example was tested for its sensoryproperties and compared to natural tea material used for the experimentas described above. Both products were used to make tea. For allsamples, the total infusion time in hot water (90° C.) was 5 minutes.Same weights of tea material (2 grs) and identical experimentalconditions were used: a beaker containing 200 ml water was heated at 90°C. and tea materials were immersed into water. Then, after 5 minutes,sensory profile of both products was performed. The result isgraphically shown in FIG. 17 .

The experiment shows that the two products are very different. The coloris rather yellow for reconstituted product and green for the originalblend. The taste is on the herbal side for the original blend and moreon the baked side for the reconstituted material. Globally, taste andodor are higher for the original blend. Taste and odor can, however beadjusted and increased for the reconstituted material by increasingsoluble content of reconstituted material or by adding ingredients suchas food flavors, food dyes or other plant extracts having color andaroma properties.

Also, same reconstituted product was used for cooking purposes. A sheetof product was put onto the surface of chicken breast and rolled so toplace the product in the middle of the meat as illustrated in FIG. 22 .Chicken was then cooked. Evaluation showed a distinctive and pleasanttaste of herbs.

Example 16

Reconstitution of Mint Leaves

A reconstituted product was made according to the following method: Mint(Mentha x piperita) was initially heated at 85° C. for 20 minutes with amint/water ratio of 1 to 5 by weight. This was followed by an extractionstep in a hydraulic press to separate the aqueous portion from therooibos fiber portion. The recovered mint fiber portion was again heatedat 85° C. for 10 minutes with a mint/water ratio of 1 to 5 by weight.After an additional extraction (by pressing), the fibrous portion wasthen refined in a Valley beater at 1.4% consistency for 10 minutes.After refining, cellulosic fibers (a blend of abaca, hardwood andsoftwood pulps, with the respective ratios: 60/10/30) were added to themint fibrous residue with a mint fiber/woodpulp ratio of 5 to 1 inweight and a wet strength agent was then added to the fibrous portion ata level of 5% w/w in order to make hand sheets. The aqueous portion wasconcentrated in an evaporator to a solid concentration of 50% and thencoated on a hand sheet on a manual size-press. In this example, theproduct was produced at 50% extract content, which is the solublecontent of the starting material of the experiment. The coated handsheets were dried on a plate dryer.

The product obtained in this example was tested for its sensoryproperties and compared to natural mint material used for the experimentas described above. Both products were used to make a mint beverage. Forall samples, the total infusion time in hot water (90° C.) was 5minutes. Same weights of mint material (2 grs) and identicalexperimental conditions were used: a beaker containing 200 ml water washeated at 90° C. and mint material was immersed into water. Then, after5 minutes, sensory profile of both products was performed. The result isgraphically shown in FIG. 18 .

The experiment shows that in the reconstituted product,freshness/menthol notes have been reduced vs original mint material;however, overall taste is stronger.

Example 17

Reconstitution of Mint (Mentha x Piperita) and Green Tea Leaves(Camellia sinensis)

A reconstituted product was made according to the following method: Mint(Mentha x piperita) and Green Tea leaves (Camellia sinensis) naturalleaves were initially blended with a ratio of 50/50 and aforementionedblend was heated at 85° C. for 20 minutes with a blend/water ratio of 1to 5 by weight. This was followed by an extraction step in a hydraulicpress to separate the aqueous portion from the blend fiber portion. Therecovered blend fiber portion was again heated at 85° C. for 10 minuteswith a blend/water ratio of 1 to 5 by weight. After an additionalextraction (by pressing), the fibrous portion was then refined in aValley beater at 1.4% consistency for 10 minutes. After refining,cellulosic fibers (a blend of abaca, hardwood and softwood pulps, withthe respective ratios: 60/10/30) were added to the blend fibrous residuewith a blend fiber/wood pulp ratio of 5 to 1 in weight in order to makehand sheets. The aqueous portion was concentrated in an evaporator to asolid concentration of 50% and L-menthol was added to the solution at 6%and then coated on a hand sheet on a manual size-press. In this example,the product was produced at 35% extract content, which is the balancedsoluble content of the materials of the experiment. The coated handsheets were dried on a plate dryer.

The product obtained in this example was tested for its sensoryproperties and compared to natural blend material used for theexperiment as described above. Both products were used to make theinfusion. For all samples, the total infusion time in hot water (90° C.)was 5 minutes. Same weights of material (2 grs) and identicalexperimental conditions were used: a beaker containing 200 ml water washeated at 90° C. and blend was immersed into water. Then, after 5minutes, sensory profile of both products was performed. The result isgraphically shown in FIG. 19 .

Example 18

Removal of Caffeine from Tea Leaves Thanks to the Reconstitution Process

In order to illustrate the potential of the invention to reduce theamount of specific components from tea, a treatment to decrease caffeinecontent from tea was developed and tested at the lab scale.

Literature shows that alkaloids compounds such as caffeine are extractedin the soluble portion. Therefore, experiment has been run on the liquorpart of tea, after separation step.

A black tea was initially heated at 85° C. for 20 minutes with atea/water ratio of 1 to 5 by weight. This was followed by an extractionstep in a hydraulic press to separate the aqueous portion from the teafiber portion. The aqueous portion of tea was then mixed with activatedcharcoal in powder form. Approx. 23 g of activated charcoal was added to500 ml of tea liquor and mixed at 60° C., stirred at 350 rpm for 1 hour.After filtration, caffeine levels in liquors were measured then throughLC-MS method.

The following samples were produced:

-   -   Control: standard tea liquor without activated charcoal        treatment    -   A: Tea liquor treated with activated charcoal Acticarbone P13        from CECA    -   B: Tea liquor treated with activated charcoal Acticarbone 2SW        from CECA    -   C: Tea liquor treated with activated charcoal Acticarbone 3 SA        from CECA    -   D: Tea liquor treated with activated charcoal Acticarbone CPL        from CECA        Caffeine contents in tea liquors are as follows:    -   Control: 22700 mg/Kg    -   A: <10 mg/Kg    -   B: <10 mg/Kg    -   C: <10 mg/Kg    -   D: <14 mg/Kg

It can be seen that caffeine levels are strongly reduced by usingactivated charcoal on tea liquor.

Example 19

Reduction of microbiological load of tea through the reconstitutedprocess

Reconstituted tea material produced during experiment 7 was analyzed vsoriginal tea material. Bacteria counts were run (Aerobic Plate Countafter 48 hrs at 30° C.). Results are shown in the following table:

Total Aerobic bacteria count (units/grs) Original tea material 8.3 10⁴Reconstituted teas 1.4 10³

Results show that reconstitution process does reduce the microbiologicalload. Temperatures applied all along the process have a lethal effect ofmicroorganisms.

Example 20

Reconstituted material was produced in different physical shapes thatprovide for different kinds of applications. Specifically, the productsshown in FIG. 20 are examples that allow for convenient preparation oftea infusions.

Example 21

A reconstituted product was made according to the following method:coffee (Coffea spp) was initially heated at 60° C. for 20 minutes with acoffee/water ratio of 1 to 5 by weight. This was followed by anextraction step in a hydraulic press to separate the aqueous portionfrom the coffee fiber portion. The recovered coffee fiber portion wasagain heated at 60° C. for 10 minutes with a coffee/water ratio of 1 to5 by weight. After an additional extraction (by pressing), the fibrousportion was then refined in a Valley beater at 1.4% consistency for 10minutes. After refining, cellulosic fibers (a blend of abaca, hardwoodand softwood pulps, with the respective ratios: 60/10/30) were added tothe coffee fibrous residue with a coffee fiber/woodpulp ratio of 5 to 1in weight and a wet strength agent was then added to the fibrous portionat a level of 5% w/w in order to make hand sheets. The aqueous portionwas concentrated in an evaporator to a solid concentration of 50% andthen coated on a hand sheet on a manual size-press. In this example, theproduct was produced at 30% extract content, which is the solublecontent of the starting material of the experiment. The coated handsheets were dried on a plate dryer.

The product obtained in this example was tested for its properties inpreparing coffee and compared to original material. Both products wereused to make coffee, and the optical density of the solution (coffee)was measured at 274 nm. For all samples, the total infusion time in hotwater (90° C.) was 5 minutes. Same weights of coffee material (2.5 grs)and identical experimental conditions were used: a beaker containing 500ml water was heated at 90° C. At T=0, ie. upon start of the experiment,heating was stopped and a coffee strip was immersed into water. A rotarymagnet was used to homogenize the content of the beaker during theentire experiment.

Samples of water were taken regularly and up to 5 minutes. Then, theoptical density of the sample was determined using a spectrophotometerat the wavelength of 274 nm (maximum absorption of caffeine). Thereference/blank test was run with a sample of clear water heated at 90°C.

The result is graphically shown in FIG. 21 below.

While infusion prepared with original coffee material is faster duringthe first 50 seconds, after 1 minute, infusion profiles of both samplesare similar.

Example 22

Reconstitution of Cocoa Shells

A reconstituted product was made according to the following method:cocoa shells (Theobroma cacao) were initially heated at 60° C. for 20minutes with a cocoa shell/water ratio of 1 to 5 by weight. This wasfollowed by an extraction step in a hydraulic press to separate theaqueous portion from the cocoa shell fiber portion. The recovered cocoashell fiber portion was again heated at 60° C. for 10 minutes with acocoa shell/water ratio of 1 to 5 by weight. After an additionalextraction (by pressing), the fibrous portion was then refined in aValley beater at 1.4% consistency for 10 minutes. After refining,cellulosic fibers (a blend of abaca, hardwood and softwood pulps, withthe respective ratios: 60/10/30) were added to the cocoa shell fibrousresidue with a cocoa shell/woodpulp ratio of 5 to 1 in weight and a wetstrength agent was then added to the fibrous portion at a level of 5%w/w in order to make hand sheets. The aqueous portion was concentratedin an evaporator to a solid concentration of 50% and then coated on ahand sheet on a manual size-press. In this example, the product wasproduced at 34% extract content, which is the soluble content of thestarting material of the experiment. The coated hand sheets were driedon a plate dryer.

The invention claimed is:
 1. A method for producing a product comprisinga fibrous plant product and a plant extract applied to the fibrous plantproduct, the method comprising: a) extracting one or more substances ofat least one plant to obtain a plant extract; b) separating the plantextract from the at least partially fibrous residue; c) optionallyrefining the residue; d) preparing a sheet like product from theresidue; e) optionally concentrating, purifying, or aromatizing theplant extract; f) applying the plant extract of step b) or step e) tothe sheet of step d); and g) optionally drying the product of step f).2. The method of claim 1, wherein step a) comprises extracting one ormore substances with a solvent.
 3. The method of claim 1, wherein stepa) comprises extracting one or more substances with pressure.
 4. Themethod of claim 1, wherein the extracting step is performed usingcomponents of a single plant or of a blend of plants.
 5. The method ofclaim 1, wherein the at least partially fibrous residue is mixed with anat least partially fibrous part of at least one further plant prior topreparing the sheet.
 6. The method of claim 1, wherein the at leastpartially fibrous residue is mixed with a stabilizer prior to preparingthe sheet.
 7. The method of claim 1, wherein the plant extract of stepb) or step e) is mixed with a plant extract of at least one furtherplant prior to applying the plant extract to the sheet.
 8. The method ofclaim 1, wherein the plant extract of step b) or step e) is mixed with atexturing agent prior to applying the plant extract to the sheet.
 9. Themethod of claim 1, further comprising: adding or removing ingredientsfrom the plant extract prior to applying the plant extract of step b) orstep e) to the sheet of step d).
 10. The method of claim 1, furthercomprising: adding or removing ingredients from the at least partiallyfibrous residue prior to applying the plant extract of step b) or stepe) to the sheet of step d).
 11. The method of claim 1, furthercomprising: processing the product of step g) to obtain regularly orirregularly shaped forms, a powder, a cream, a slurry, a paste, a foam,a liquid, a tablet, a pellet, or a granule.
 12. The method of claim 1,wherein the plant is selected from the group consisting of herbs,medicinal plants, tea, vegetables, and spices.